Bending Marshall Oldham Ryan Turner Sarah Reiss Prepared for - PowerPoint PPT Presentation

Geothermal Pipe Bending Marshall Oldham Ryan Turner Sarah Reiss Prepared for Charles Machine Works, Inc.

Mission Statement D.T.E. is dedicated to coming up with creative and innovative designs with our client’s satisfaction as our top priority. We are devoted to designing solutions that are cost efficient, reliable, and exceed all expectations. We promise to put our client’s needs first through the entirety of the project. Our innovation can make your engineering dreams come to life.

Problem Introduction • Basic Ground Source Heat Pump System • 250,000 systems installed each year worldwide  50,000 in United States in 2010 • Geothermal energy falls under space heating and cooling, a 1.9 billion dollar industry. • Growth rate expected to rise from 2.1% to 3.4% through 2016.

Problem Introduction • Current Design  Single U-Loop  Packed with 240 gallons of grout  Grout is a poor heat conductor

Problem Introduction • Current Design Single pipe with outer  return Packed with 200  gallons of Grout 19% Reduction of grout  from single U-Loop

Problem Statement • Feasibility of Bending  4.5 inch outer diameter HDPE pipe in “U” shape • Design and build a machine that will: Bend the HDPE pipe  Insert a 1 inch grout line into the “U” of the  bend Band the bent pipe and grout line for  spooling

Problem Statement Introduction • Reduce the outer diameter of the pipe • Allows for smaller diameter holes (approximately 4.5 inch diameter hole) • Reduces the amount of grout used to 30 gallons • 88% reduction from Single U-Loop • Less grout=better efficiency

Deliverables • Geothermal Pipe Bending Machine  Fold HDPE SDR 21 pipe with a 4.5 inch outer diameter  300 feet of pipe in approximately 30 minutes  Finished pipe will be banded in a “U” shape with a 1” grout line  Bands must break at 100 PSI  Operable by one person

Task List • 1.0 -Testing  1.1 Create test dies to test the pipe in the Instron machine  1.2 Test the pipe  1.3 Gather data and analyze to determine whether the dies are feasible  1.4 Analyze the forces observed by the frame  1.5 Test the amount of force required to push pipe  1.6 Develop a drive train to apply the required force to the pipe  1.7 Test pipe for forces required to keep in U-Shape  1.8 Design band to apply forces to keep the pipe in the U-Shape

Task List • 2.0 - Pipe Bending Machine  2.1 Dies for bending pipe  2.2 Die driving mechanism  2.3 Design Frame  2.4 Drive mechanism  2.5 Grout line insert mechanism  2.6 Bands for holding the pipe in “U” Shape  2.7 Banding mechanism  2.8 Mechanism for putting bent and banded pipe on reel

Task List • 3.0 - Documentation  3.1 Drafting  3.2 Write design report  3.3 Gantt charts and MS Project  3.4 SolidWorks drawings • 4.0 - Engineering Review and Approval  4.1 Review and approve engineering  4.2 Review, approve, and finalize drawings • 5.0 - Fabricate and Procure System Materials  5.1 Procure Materials  5.2 Fabricate frame and full assembly • 6.0 - Integration of system  6.1 Deliver to Charles Machine Works  6.2 Functional checks

Market Research • 250,000 systems installed each year worldwide • 50,000 in United States in 2010 • Potentially 45,000,000 feet of geothermal casing in U.S. • Primary customers will be commercial heating and cooling contractors. • Secondary customers will be end-users or home- owners/builders.

Patents • Before 1992: 4986951, 4863365, 4998871, 5091137  Relation or continuation of each other  Describes a method for bending circular cross sectional shaped pipe liner  Pipe liner is deformed through a process involving rollers and heat  Then placed in pipe for lining and is pressurized and heated to re-expand

Patents • After 1992 : 5342570, 5861116, 6119501 5342570 , 6119501  Describes a process to deform  pipe liners to line new and old pipe into U-shape Main differences include  unusual shaped rollers and application of heat and cooling during the deformation process 5861116  Similar process that is described  above but pipe liner is deformed into a “W” shape

Design Concepts • Design I • Design II • Both designs include:  Bending Geothermal HDPE pipe into “U”  Grout Line Incorporation  Banding Mechanism

Design Concept I: • Bending Geothermal HDPE pipe into “U” • No vertical separation between the die sets Die Set Guide Pipe Hydraulic Motor

Design Concept II: • Vertical separation between the die sets • The pipe reel will assist in pulling the pipe through the die set • Added cost of hydraulic cylinders

Hydraulic Motors • Placed at the beginning of the machine to push the pipe into the dies • Equipped with rubber disk to create friction • 4 Options: • Design Concept 1: Slow or Fast • Design Concept 2: Slow or Fast

Dies • Initial Die Assembly  8 dies  1 inch wide  6 inch diameter

Dies • Top Dies  8 dies  1 inch wide  7.5 or 6.0 inch diameter  Step down in increments of ½ inch for every 8.5 inches of linear travel  Reduces the height of the pipe by 3.75 inches (brings the top of the pipe in contact with the bottom) • Bottom Dies A saddle for the 4.5 outer  diameter pipe Adjustable 

How to Calculate Forces Required to Move Pipe through System • 𝐺 𝑠𝑓𝑟𝑣𝑗𝑠𝑓𝑒 = 2 ∗ 𝐺 𝑜 ∗ µ + 𝐺 𝑠𝑝𝑚𝑚𝑓𝑠 cos(𝜄) • 𝐺 𝑢𝑝𝑢𝑏𝑚 = 𝐺 𝑠𝑓𝑟𝑣𝑗𝑠𝑓𝑒

How to Calculate Forces Required to Move Pipe through System • Design Concept I: • Design Concept II:

How to Calculate Forces Required to Move Pipe through System • Testing on the Instron Machine

How to Calculate Forces Required to Move Pipe through System Force Required to Move Pipe Equation Values Units Coefficient of Friction (c f ) User Input 0.3 Angle of Force ( θ) User Input 33.56 degrees Percent Change User Input 84.56% percent 800 lb f Max Force User Input Force Required (f required ) Roller Force (f) Units Equation Units 1 321 lb f 460.092 lb f Actual forces for each roller 2 505 lb f 723.820 lb f 3 460 lb f 659.321 lb f 4 421 lb f 603.422 lb f 𝑠𝑓𝑟𝑣𝑗𝑠𝑓𝑒 = 2 ∗ ∗ + ∗ cos ( ) 5 423 lb f 606.289 lb f 6 427 lb f 612.022 lb f 7 442 lb f 633.522 lb f 8 455 lb f 652.155 lb f 3454 lb f 4950.644 lb f 1-8

Force Required to Move Pipe through System Force required to move pipe through system Design Speed of system Actual Force Force with 1.5 Safety Factor Fast (25 fpm) 5078.609 in*lb f 7617.913 in*lb f Split Design 4294.471 in*lb f 6441.707 in*lb f Slow (10 fpm) Fast (25 fpm) 4950.644 in*lb f 7425.966 in*lb f Solid Design 4186.264 in*lb f 6279.396 in*lb f Slow (10 fpm)

How To Calculate Torque • Design Concept 1: 𝐺 𝑢𝑝𝑢𝑏𝑚 /2  𝐺 𝑠𝑝𝑚𝑚𝑓𝑠 = 𝜈+cos(𝜄) • Design Concept 2: 𝐺 𝑢𝑝𝑢𝑏𝑚 /4  𝐺 𝑠𝑝𝑚𝑚𝑓𝑠 = 𝜈+cos(𝜄) 𝑒 • 𝜐 = 𝐺 𝑠𝑝𝑚𝑚𝑓𝑠 ∗ 2

How to Calculate Torque Torque Required for Drive Motors Equation Values Units Diameter of Roller User Input 8 in Coefficient of Friction [between drive roller and pipe] (c f ) User Input 0.8 Angle of Force between drive roller and pipe ( θ) User Input 5 degrees Total force for equal max force on all rollers From Force on Rollers Sheet 9173.167 lb f Total force for actual forces for each roller From Force on Rollers Sheet 4950.644 lb f Split Design Total force for % of actual forces for each roller From Force on Rollers Sheet 4186.264 lb f Max Force From Force on Rollers Sheet 800 lb f Percent Change From Force on Rollers Sheet 84.56% Percent Normal Force exerted by roller (Max) 1276.750 lb f 𝑠𝑝𝑚𝑚𝑓𝑠 𝑜 = Normal Force exerted by roller (Actual) 689.046 lb f µ + cos 582.657 lb f Normal Force exerted by roller (% Actual) Torque of motor to produce force required (Max) 5107.000 in*lb f = 𝑜 ∗ Torque of motor to produce force required (Actual) 2756.184 in*lb f 2330.629 in*lb f Torque of motor to produce force required (% Actual)

Torque Required for Drive Motor Torque of motor to produce force required Design Speed of system Actual Torque Torque with 1.5 Safety Factor Fast (25 fpm) 2827.427 in*lb f 4241.140 in*lb f Split Design 2390.872 in*lb f 3586.308 in*lb f Slow (10 fpm) Fast (25 fpm) 5512.369 in*lb f 8268.554 in*lb f Solid Design 4661.259 in*lb f 6991.889 in*lb f Slow (10 fpm)

Drive System • Three Options  Direct Drive  Gear Driven  Chain Driven

Drive System Torque of Pump Speed of Pump Displacement Ratio Final Torque Drive System Design RPM PSI Price System Series (in 3 ) (in*lb f ) (in*lbf) Fast (25 fpm) 4000 12.5 3860 12 2500 1:1 3860 $800.00 Split Slow (10 fpm) 4000 30 3825 5 1000 1:1 3825 $850.00 Direct Drive Fast (25 fpm) 6000 49 12539 12 2000 1:1 12539 $1,300.00 Solid Slow (10 fpm) 6000 45 11121 5 2000 1:1 11121 $1,300.00 Fast (25 fpm) 4000 24 6000 14 2000 6:5 7200 $850.00 Gear Drive Split Slow (10 fpm) 2000 11.9 2720 7 2000 3:4 3808 $400.00 or Fast (25 fpm) 4000 30 8375 19 2000 3:2 13260 $800.00 Chain Driven Solid Slow (10 fpm) 2000 24 5880 6 2000 6:5 7056 $550.00